Tier I Level Emissions Engine Repower for the D10N Track-Type Tractor {1000, 7000} Caterpillar

Track-Type Tractor

D10N (S/N: 2YD1-UP; 3SK1-UP)

Introduction

This Special Instruction provides the procedure in order to repower a D10N Track-Type Tractor. The replacement engine will be a Tier I level 3412 DITA engine. Refer to Table 1 for the engine arrangement numbers. The D10N Track-Type Tractor was originally equipped with a 3412 engine. The original 3412 engine is not regulated for emissions. This Special Instruction will provide the information in order to install the Tier I level replacement engine.

This Special Instruction does not include procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.

When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

Reference: Service Manual, Parts Manual, Operation and Maintenance Manual.

Note: This instruction contains some procedures that come from dealer feedback. The emissions replacement engine is not a direct replacement. Additional parts and labor hours may be needed to complete this engine replacement. Variations in machine serial number breaks or options could cause discrepancy in the modifications, required parts, and labor hours to complete this procedure. This documentation is a guideline for Cat Dealer personnel in order to complete the repower procedure. If errors are found, submit feedback in SIS Web or contact the Emissions Solutions Group. The following information will be required:

• Machine serial number

• Original engine arrangement number

• Original engine serial number

• Emissions engine arrangement number

• Details of the error

• Photos of the error and photos after the proposed solution

Registering the Retrofit

Reference: Special Instruction, REHS5097, "Instructions to Register the Retrofit"

Documenting changes to a machine configuration is an advantage to Caterpillar and the dealer technicians that are sent to repair a machine. By identifying that the machine has been reconfigured, the technician will have a better opportunity to have the correct parts, tooling, and service information. Identifying that the machine has been reconfigured will also allow Caterpillar to include the retrofitted serial numbers in applicable Service Letters.

Safety

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Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

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Do not attempt to assemble this machine until you read and you understand the assembly instructions. Improper assembly procedures could result in injury or death.

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Personal injury or death can result from improper lifting or blocking. When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component. Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Welding on Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.

1. Set the engine control to the STOP mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

4. Disconnect the engine electronic components from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor bypass and the fuel metering valve and sensors

5. Protect the wiring harnesses from welding debris and/or from welding spatter.
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   NOTICE
   Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

6. Connect the ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld in order to reduce the possibility of welding current damage.

7. Use standard welding procedures to weld the materials together.

Required Parts

Refer to Parts Manual, SEBP5298.

Note: The required parts are subject to some change. Refer to TMI for the most recent required parts list.

Note: If part fabrication is necessary, ensure that all fabricated parts are deburred. Use caution when deburring parts. Avoid excessive grinding and notches.

Note: A breakdown of the kit provides a parts list for the repower. The kit part number is not serviceable. Order the engine arrangement plus the list of parts provided in the kit.

Original Machine Cycle Times

Record the cycle times for the original machine. Refer to the Service Manual for your particular machine to record cycle times.

Original Machine Stall Speed (If Applicable)

1. Record the stall speed for the original machine.

2. Refer to SIS for Techniques for loading engines, SEHS7050.

3. Refer to the Service Manual for your particular machine order to record stall speed.

Preparation of the Machine

1. Wash the machine.

2. Remove the hood, the guards, and the belly guard.

3. Drain the coolant into a suitable container and disconnect the water lines.

4. Drain the engine oil into a suitable container.

5. Remove the engine oil filter and the fuel filters.

6. Remove the air cleaner.

7. Disconnect any remaining lines that connect the engine to the machine. Disconnect any wires that connect the engine to the machine.

8. Disconnect all other lines, wires, or parts that connect the engine to the machine.

Removal of the Original Engine

1. Before removal, measure the position of the crankshaft from the centerline to both the right and the left frame rails. Also measure the height from the centerline of the crankshaft to the top of the main frame.

2. Remove the original engine. Refer to the Service Manual for your particular machine in order to remove the engine.

Removal of Parts From Original Engine

1. Remove the following parts from the original engine and inspect and replace parts as required.

   • Crankshaft Pulley Group

   • Belt Tightener Group

   • Fan Drive Group

   • Rear Engine Support Group

   • Compressor Group - Refrigerant

   • Torque Converter Group

   • Yoke Group

   • Hydraulic Pump Group and Required Lines

Engine Preparation

Note: Many of the following steps use parts from the original engine. Inspect all components that are used from the original engine. Repair any damaged components or replace any damaged components.

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Illustration 1	g01624407
(1) 7W-2867 Crankshaft Pulley Gp

1. Install the original (1) Crankshaft Pulley Gp.
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   Illustration 2	g01624410
   (2) Fan Drive Group

2. Install the original fan drive group (2). A new 7W-1665 V-Belt Set is required for this installation.
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   Illustration 3	g01624706
   (3) Belt Tightener Group

3. Install the original belt tightener group (3).
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   Illustration 4	g01624709

4. Install the original alternator group (4). A new 7W-6129 V-Belt (5) is required for this installation.

   Note: If the machine is not equipped with an air conditioner, proceed to Step 6.

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   Illustration 5	g01624711

5. Install the original refrigerant compressor (6).
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   Illustration 6	g01624719

6. Install the original rear support group (7). Replace the old mount assemblies (8).
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   Illustration 7	g01624777

7. Install the original starting motor group (9). A new 7N-6494 Gasket (10) is required for this installation.
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   Illustration 8	g01624785
   View of 130-9199 Manifold Shield

8. Install the 130-9199 Manifold Shield. Refer to the D10R (S/N: 3KR) for parts.
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   Illustration 9	g01624820
   View of 125-5825 Fumes Disposal Gp

9. Install the 125-5825 Fumes Disposal Gp. Refer to the D10R (S/N: 3KR) for parts information.
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   Illustration 10	g01624821

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   Illustration 11	g01624822

10. Fabricate a riser plate (11). The riser plate will shift up the water separator (12).
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    Illustration 12	g01624900

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    Illustration 13	g01624930

11. Install the 162-2458 Fuel Priming Pump and Primary Filter Gp (13). Refer to the 775E (S/N: BEC) for parts information.
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    Illustration 14	g01624941
    View of 138-1224 Coolant Conditioner Gp

12. Install the 138-1224 Coolant Conditioner Gp. Refer to the D10R (S/N: 3KR) for parts information. The Coolant Conditioner GP is optional if the machine is not using ELC.
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    Illustration 15	g01625151
    View of Torque Converter Gp

13. Install the original torque converter group. There are two 8M-4433 O-Ring Seals (14) and a 3D-8241 O-Ring Seal (15) that are required for this installation.
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    Illustration 16	g01625234
    View of 6T-3699 Power Train Oil Lines Gp

14. Install the lines group for the power train that runs between the torque converter and the oil cooler. There are two new 4J-0528 O-Ring Seals (16) that are required for this installation.
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    Illustration 17	g01625236
    View of Vane Pump Gp

15. Install the original vane pump group. A new 5F-3106 O-Ring Seal is required for this installation.
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    Illustration 18	g01625237

16. Install other required lines before installing the engine.
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    Illustration 19	g01645426
    View of yoke

17. The repower engine is configured for the D10N (S/N: 3SK) yoke setup. The D10N (S/N: 2YD) must swap out the yoke to avoid any issues with the pump couplings

Engine Installation

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Illustration 20	g01625245

1. Install the replacement engine (1) in the original mounting location.
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   Illustration 21	g03507489

2. Install original fan blower group and inspect the fan spider and replace as necessary.
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   Illustration 22	g01625372
   View of 7W-2871 Radiator Gp

3. Install the original 7W-2871 Radiator Gp (2). Install the following new parts: Four 9B-4179 Hoses, Eight 5P-4868 Hose Clamps, One 5D-6005 Hose and Four 5P-1717 Hose Clamps.
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   Illustration 23	g01625380

4. Install the original pump coupling or auxiliary drive shaft (3).

   Note: If coupling does not fit, check yoke setup.

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   Illustration 24	g01625381

5. Install the original main drive shaft (4).
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   Illustration 25	g01625617

6. Install the original guard group for the drive shaft guard group (5).
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   Illustration 26	g01625887
   View of Hydraulic Control Ar

7. Connect the hydraulic pump to the tank and the implement circuit. Install the following new parts: 2S-4078 O-Ring Seal Qty - one, 3J-1907 O-Ring Seal Qty - one, 4J-0524 O-Ring Seal Qty - one and 2H-3934 O-Ring Seal Qty - one
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   Illustration 27	g01625891

8. Install the 310-1144 Jumper Harness As (6) on the new engine and route as required. Secure the harness in multiple locations. Refer to the Repower Electrical Schematic, UENR5443.
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   Illustration 28	g01625897

9. Install the following parts: 318-1181 Speed Sensor Gp (7), 1V-6431 Seal (8) and 091-1745 Washer (9). Connect the 310-1144 Engine Harness As connector. The extension of the connector might be required in some cases. Refer to the Repower Electrical Schematic, UENR5443.
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   Illustration 29	g01625898

10. Install the original guards and hood (10).
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    Illustration 30	g01625899

11. Install the original 8N-0745 Muffler Gp (11)
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    Illustration 31	g01626132

12. Install the original air lines. Replace the parts in area A with the following: 3B-6552 Pipe Elbow (12), 9X-0263 Adapter (13), 3J-7354 O-Ring Seal (14) and 161-9926 Pressure Sensor Gp (15). Install the following new parts: 8N-2730 Metal Seal Ring (16) Qty - one, 8N-2729 Metal Seal Ring (17) Qty - one, 8N-2745 Clamp (18) Qty - one, 2M-5173 O-Ring Seals (19) Qty - one and 1W-6694 Clamp As (20) Qty - one.
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    Illustration 32	g01626136

13. Install the original air cleaner (21). Install the following new parts: 6N-3356 Hose (22) Qty - one and 3E-7447 Hose Clamps (23) Qty - one.
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    Illustration 33	g01626143

14. Install the original 7W-9380 Dust Ejector Gp (24). Install the following new parts: 7W-1208 Clamp (25) Qty - one, 7W-2478 Gasket (26) Qty - one, 5P-4868 Hose Clamps (27) and 7W-9381 Hose (28) Qty - one.
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    Illustration 34	g01626145

15. Connect the pigtail of the 161-9926 Pressure Sensor Gp (29) to the connector of the 310-1144 Engine Harness As (30).

Cab Modifications

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Illustration 35	g01626335

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Illustration 36	g01627736

1. Mount the 9W-1951 Connector Receptacle (1) and the 8C-6354 Receptacle Cap (2) to the lower left of the dash. The pin position is show in Illustration 36
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   Illustration 37	g01626336

2. Install the 121-2843 Switch Harness As (3) 3E-9044 Rocker Switch (4) on the right-hand console. Additional wires might be needed to connect to the 310-1144 Jumper Harness. Refer to the Repower electric Schematic, UENR5443.
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   Illustration 38	g01626337

3. Install the 125-3420 Decelerator Control (5) on the lower right side of the dash. Connect the decelerator control to the connector for the 310-1144 Engine Harness As. Refer to the D10R (S/N: 3KR) for parts.
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   Illustration 39	g01626338
   (6) Decelerator Pedal Connector

4. Reconnect the original EMS harness and sensors.
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   Illustration 40	g01626339

5. Create jumper wires to connect to the ECM power supply with main power relay. Refer to the repower electrical Schematic, UENR5443.
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   Illustration 41	g01626340

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   Illustration 42	g01626341

6. Install the 6T-3643 Circuit Breaker As on the left side of the dash.

7. Connect the harness as shown in Schematic, UENR5443. Additional wires will have to be created.

Adjustment Procedures

1. Adjust the pedal with the following steps:
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   Illustration 43	g01626342
   (1) Pedal Stop (2) Pedal (3) Setscrew (4) 15 mm (0.59055 inch)

   1. With the pedal stop (1) set to 15 mm (0.59055 inch) (4) adjust the pedal (2) on the splined shaft to position tread surface to 15 mm (0.59055 inch).

   2. Run the engine at high idle. Screw in and lock the setscrew (3) so that the engine decelerates to 1000 ± 50 RPM when the pedal is depressed.

   3. Release the pedal. With the pedal released, check the high idle RPM against the initial high idle reading. Screw in and lock setscrew (1). Allow 5 ± 3 free play at the end of pedal (2).

Repower Machine Cycle Times

1. Refer to the Service Manual for your particular machine in order to record cycle times.

2. Record and compare the cycle times between the original machine and the repower machine.

Repower Machine Stall Speed

Refer to SIS for Special Instruction, SEHS7050-00, "Techniques for Loading Engines".

1. Refer to the Service Manual for your particular machine in order to record the stall speed.

2. Record and compare the stall speed between the original machine and the repower machine.